What is Intelligent Motor Control for Large Fans and Pumps?
Intelligent Motor Control is a cutting-edge solution designed specifically for large fans and pumps in mining and metals industries. It manages motors up to 90MW currently under control, focusing on both low voltage and high voltage systems (up to 13.8kV). This includes a variety of fans such as C/T fans, ID/FD fans, bagging house fans, boiler feed pumps, vacuum pumps, and ventilation fans commonly found in mining operations. The system is delivered as an Energy Efficiency As-a-Service model, meaning clients get zero-capex installation and operation, with guaranteed minimum net GWh savings contractually promised. The approach combines expertise in design, assembly, integration, and maintenance, all while ensuring the client’s staff remains focused on production.
Main Benefits of Intelligent Motor Control
The benefits of this system are impressive and measurable. Here are some key figures and facts that highlight its impact:
- 43% average energy efficiency improvement
- 54 energy houses (e-houses) deployed to date
- Over 1 billion kWh energy saved so far (1,006,992,769 kWh)
- 1.47 billion litres of water saved
- 1,080 tonnes of emissions reduced
- 745 tonnes of coal and ash saved
- Equivalent to powering 19,720 households monthly
- Contractual guarantees with savings assessment in less than 18 months
How the Project Ensures Production Uptime
One of the standout features of the Intelligent Motor Control system is its focus on production uptime. The e-houses are installed with a fully motorized bypass, which means zero risk of unplanned downtime. This is critical in mining and metals industries where any unexpected halt can be costly. The system also includes sealed energy meters for precise consumption measurement, verified against third-party baselines to ensure the savings are real and transparent. This combination of reliability and accountability makes it a trusted solution for energy-intensive users.
Client Success Stories and Industry Impact
Major industry players have seen tangible benefits from adopting this technology. For example, ArcelorMittal has scaled its involvement since 2016, with Energy Drive delivering energy-saving solutions that not only reduce base energy usage and carbon footprint but also improve system reliability and availability. Jacques Bezuidenhout, Electrical Maintenance Engineer at ArcelorMittal, praises the solution for enhancing their descaling system’s performance. Similarly, Sibanye-Stillwater has benefited from significant electricity and Scope 2 emissions reductions since 2021, with cash flow savings helping to offset rising commodity prices and inflation. Reghardt Pretorius, VP Engineering at Sibanye-Stillwater, highlights how operating costs and emissions have both been reduced, supporting broader industry sustainability goals.
Engineering and Electrical Expertise Behind the System
The project combines deep engineering and electrical expertise with proven models of medium voltage motor control systems. This includes everything from design and assembly to integration and ongoing maintenance. The approach ensures that the client’s operational staff can stay focused on production without disruption. The system’s design prioritizes seamless integration and operational reliability, making it a practical and effective solution for energy-intensive industries looking to optimize their energy spend on large motors.
Project Impact on Sustainable Development Goals (SDGs)
- SDG 7: Affordable and Clean Energy – by improving energy efficiency and reducing consumption
- SDG 9: Industry, Innovation, and Infrastructure – through advanced motor control technology and infrastructure deployment
- SDG 12: Responsible Consumption and Production – by lowering emissions and resource use
- SDG 13: Climate Action – via significant reductions in carbon footprint and emissions
- SDG 6: Clean Water and Sanitation – through substantial water savings
Energy Efficiency as a Service: A Zero-Capex Solution
This project operates on an Energy Efficiency as-a-Service model, which means clients don’t have to worry about upfront capital expenditure. The entire system is fully funded and operated by the service provider, delivering guaranteed energy savings with minimal risk. The assessment phase is quick, with a go/no-go decision made in under 30 days, and new accounts typically onboarded within 3 to 6 months. Expansion projects can be completed in less than 45 days, and operational e-houses are deployed within 6 to 12 months. Contracts include a 10-year service level agreement, after which clients can opt for a reduced fee SLA or purchase the e-house outright. This flexible, client-friendly approach makes advanced energy savings accessible and hassle-free.
